Gas burner assemblies, methods for assembling, and gas fired appliances employing same

ABSTRACT

A gas burner assembly includes in one embodiment a top plate having at least one port for discharging fuel and a downwardly-depending, peripheral edge having a plurality of spaced-apart slots, and a bottom base having a peripheral edge disposed within the downwardly-depending peripheral edge of the top plate. A gasket is disposed between the base and the plate. A venturi tube is attached to the base with a tube holder. The plate is attachable to the base by displacing and/or expanding a portion of the downwardly-depending, peripheral edge adjacent the slots to form a plurality of spaced-apart, inwardly-extending tabs disposed under the peripheral edge of the base. Methods for assembling and gas fired appliances employing gas burner assemblies are also disclosed. Further, attachment means and methods for attaching a first member to a second member using such displaceable and/or expandable tabs are also disclosed.

FIELD OF THE INVENTION

This invention relates generally to gas fired appliances, and morespecifically, to gas burner assemblies for gas fired appliances.

BACKGROUND OF THE INVENTION

Gas fired appliances such as vented gas fireplace heaters have gainedwidespread popularity recently. Typically, a vented gas fireplace heaterincludes a housing having a glass front, a gas burner assembly, and aplurality of ceramic logs. The vented gas fireplace heater can be astand-alone unit with legs, and/or be installed in an existingfireplace.

Conventionally, the gas burner assembly includes a flat stainless steeltop plate connected to a cast iron bottom base with bolts. Assemblyrequires drilling vertically-extending holes in the cast iron bottombase which holes are then tapped to form screw threads for receiving thebolts. The stainless steel top plate requires drillingvertically-extending holes which correspond and align with the threadedholes installed in the cast iron bottom base. Thereafter, the bolts aretypically manually tightened to attach the stainless steel top plate tothe cast iron bottom base. Other techniques for assembling a gas burnerassembly include attaching a flat ceramic top plate to the bottom baseusing an adhesive such as a high temperature resistant siliconeadhesive.

There is a need for further gas burner assemblies and methods forassembly of gas burner assemblies for use in gas fired appliances.

SUMMARY OF THE INVENTION

In a first aspect, the present invention provides a gas burner assemblywhich includes a top plate having at least one port for discharging fueland a downwardly-depending, peripheral edge having a plurality ofspaced-apart slots, a bottom base having a peripheral edge disposedwithin the downwardly-depending, peripheral edge of the top plate, andwherein the top plate is attached to the bottom base by displacing aportion of the downwardly-depending, peripheral edge adjacent to theslots to form a plurality of spaced-apart, inwardly-extending tabsdisposed under the peripheral edge of the bottom base.

In a second aspect, the present invention provides a gas burner assemblywhich includes a top plate having at least one port for discharging fueland a downwardly-depending, peripheral edge having a plurality ofspaced-apart slots, a bottom base having a peripheral edge disposedwithin the downwardly-depending, peripheral edge of the top plate, agasket disposed between the bottom base and the top plate, a venturitube assembly, and a tube holder for attaching the venture tube assemblyto the bottom base. Additional features of the gas burner assembly mayinclude the distance between adjacent slots being greater than a lengthof the slots. The top plate may be attached to the bottom base byexpanding a portion of the downwardly-depending, peripheral edge underthe slots to form a plurality of spaced-apart, inwardly-extending tabsdisposed under the peripheral edge of the bottom base. The gasket andthe bottom base are sandwiched between a bottom surface of the top plateand the tabs and operable to maintain a gas tight seal between the topplate, the bottom base, and the gasket.

In a third aspect, the present invention provides gas fired applianceswhich include a housing, and the above-described gas burner assemblies.At least one ceramic log may also be disposed in the gas firedappliances.

In a fourth aspect, the present invention provides a method forassembling a gas burner assembly in which the method includespositioning a bottom base having a peripheral edge within a top platehaving at least one port and having a downwardly-depending, peripheraledge with spaced-apart slots adjacent to the periphery of the top plate.Portions of the downwardly-depending, peripheral edge of the top plateadjacent to the slots are displaced to form a plurality of spaced-aparttabs under the peripheral edge of the bottom base to attach the topplate to the bottom base.

In a fifth aspect, the present invention provides an attachment meanswhich includes a first member having a downwardly-depending, peripheraledge having a plurality of spaced-apart slots, a second member having aperipheral edge disposed within the downwardly-depending, peripheraledge of the first member, and wherein the first member is attached tothe second member by displacing a portion of the downwardly-depending,peripheral edge under the slots to form a plurality of spaced-apart,inwardly-extending tabs disposed under the peripheral edge of the secondmember, and the first member and the second member are formed fromdifferent materials having different rates of thermal expansion. Thefirst member may be attached to the second member by expanding a portionof the downwardly-depending, peripheral edge under the slots to form aplurality of spaced-apart, inwardly-extending tabs disposed under theperipheral edge of the second member. A gasket may be disposed betweenthe first member and the second member adjacent to the peripheral edge.

In a sixth aspect, the present invention provides a method for attachinga first member to a second member. The method includes positioning thesecond member having a peripheral edge within the first member having adownwardly-depending, peripheral edge with spaced-apart slots adjacentto the periphery of the first member, and expanding portions of thedownwardly-depending, peripheral edge of the first member adjacent tothe slots to form a plurality of spaced-apart tabs under the peripheraledge of the bottom base to attach the first member to the bottom base.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularlypointed out and distinctly claimed in the concluding portion of thespecification. The invention, however, may best be understood byreference to the following detailed description of various embodimentsand the accompanying drawings in which:

FIG. 1 is a perspective view of a gas fired appliance such as a ventedgas fireplace heater employing a gas burner assembly (not shown inFIG. 1) in accordance with the present invention;

FIG. 2 is an exploded perspective view of the gas burner assembly ofFIG. 1 in accordance with the present invention prior to assembly;

FIG. 3 is a perspective view of the assembled gas burner assembly ofFIG. 2 prior to attachment of the top plate to the bottom base;

FIG. 4 is a perspective view of the bottom of the assembled gas burnerassembly of FIG. 3 with the top plate attached to the bottom base;

FIG. 5 is a bottom view of the assembled gas burner assembly of FIG. 4with the top plate attached to the bottom base;

FIG. 6 is an enlarged view of detail 6 of FIG. 5 illustrating theattachment means for attaching the top plate to the bottom base;

FIG. 7 is a flowchart of a method of assembling a gas burner assembly inaccordance with the present invention;

FIGS. 8 and 9 illustrate another embodiment of an attachment means inaccordance with the present invention;

FIGS. 10 and 11 illustrate another embodiment of an attachment means inaccordance with the present invention; and

FIGS. 12 and 13 illustrate another embodiment of an attachment means inaccordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates one embodiment of a gas fired appliance such as avented gas fireplace heater 10 in accordance with the present invention.Vented gas fireplace heater 10 generally includes a housing 12 having achamber 14 therein and supported by a plurality of feet 15, a pair ofdoors 16 having glass panels, a gas burner assembly (not shown inFIG. 1) disposed in chamber 14, and at least one ceramic log 18 disposedin chamber 14 above the gas burner assembly.

FIG. 2 illustrates an exploded view of a gas burner assembly 20 inaccordance in the present invention prior to assembly, and which afterassembly, may be installed in vented gas fireplace heater 10 (FIG. 1).Gas burner assembly 20 generally includes a top plate 30, a gasket 40, abottom base 50, a venturi tube 60, and a tube holder 70.

As explained in greater detail below, the attachment technique of thepresent invention incorporates the use of tabs, eliminates the use ofbolts, compensates for the use of materials with different rates ofthermal expansion, and allows for automated and/or uniform assembly.

Top plate 30 may include a generally planar member 32 having a pluralityof ports 33 extending therethrough through which fuel such as naturalgas or propane may be discharged resulting in a desired flame picture orpattern. Top plate 30 may be initially formed and cut out from a flatplanar member. Thereafter, the plurality of ports 33 may be drilled orstamped therethrough, a plurality of spaced-apart slots 34 adjacent to aperipherally-extending edge 36 cut or punched therethrough, a roundednotch 38 removed, and the corners between the adjacent sides of the flatplanar member notched or removed. Next, the peripherally-extending edgemay be bent downwardly to form a downwardly-depending, peripheral edge39 having the plurality of space-apart slots 34 disposed therein asshown in FIG. 2. The top plate may be formed from stainless steel andcoated with a high temperature black paint.

Gasket 40 generally includes a planar member 42 having a central cutoutand a peripheral edge sized and configured for being received along thebottom surface of top plate 30 adjacent to downwardly-depending,peripheral edge 39. The gasket may be formed from a fiberglass materialsuch as 1200 Manniglass available from Lydall Industrial ThermalSolutions of Hartford Conn. or formed from other suitable materials.

Bottom base 50 includes a generally flat central portion 52 having anopening 54 for receiving a flow of fuel, a pair of threaded apertures56, and a peripheral edge or raised lip 58 which is sized and configuredfor being received along the bottom surface of top plate 30 adjacent todownwardly-depending, peripheral edge 39 with gasket 30 disposedtherebetween. The raised lip forms a chamber within the gas burnerassembly for distributing the gas and air mixture to the ports. Thebottom base may be may be formed from cast iron.

Venturi tube assembly 60 includes a venturi tube 62 and a cap 64 whichis attached to an end of venturi tube 62 to define a first aperture 66for receiving a flow of fuel and a pair of second apertures 68 forreceiving a flow of air for mixing with the flow of fuel. Tube holder 70is attached to bottom base 50 using screws 72 receivable within threadedapertures 56. The venturi tube and cap may be formed from aluminum, andthe tube holder may be formed from cast iron.

FIG. 3 illustrates assembled gas burner assembly 20 prior to securingtop plate 30 to the bottom base. For example, venturi tube assembly 60may be attached to the bottom base with tube holder 70 using the screws,and thereafter, the bottom base may be nested in top plate 30 with thegasket sandwiched therebetween.

As shown in FIGS. 4 and 5, thereafter a suitable number of tabs 35 maybe formed in top plate 30 to securely and sealably attach top plate 30to bottom base 50. As best shown in FIG. 6, a portion of thedownwardly-depending, peripheral edge under the slot is displaced orextended to form an inwardly-extending tab 35 disposed under peripheraledge 58 of bottom base 50 to sandwich the edge or lip 58 of bottom base50 and the gasket between the plurality of tabs and the bottom surfaceof top plate 50. The slot in the edge of the top plate is desirablypositioned from the distal most edge of the top plate so that thevarious components may be compressed and/or sandwiched while the tab isformed resulting in the gasket remaining compressed between the topplate and the bottom base. For example, desirably, the gasket isresilient and may be deformed upon assembly to form a gas tight sealbetween the top plate and the bottom base.

For example, the portion of the downwardly-depending, peripheral edgeunder the horizontally-extending slot may be deformed or expanded toform inwardly-extending tab 35. The plurality of inwardly-extending tabs35 may include a plurality of spaced-apart, generally inwardly extendingV-shaped tabs, or a plurality of spaced-apart, generallyinwardly-extending trapezoidally-shaped tabs. From the presentdescription, other configurations of the tabs, such as square,rectangular, curved, cut, other configurations, and combinationsthereof, may be suitably employed. In addition, the portion of thedownwardly-depending, peripheral edge under the slot may be twisted,e.g., the lowermost middle section may be forced downwardly toward thebottom base.

In addition, the distance between adjacent slots may be greater than thelength of the slots, and a suitable number of tabs may be formed toprovide a gas tight seal with or without a gasket.

The tabs may be manually formed. Alternatively, the tabs may be formedusing a hydraulically operated device having a tool such as jawsconforming to the shape of the tab and operable to apply a constantforce for uniformly forming the tabs.

As illustrated in FIG. 7, a method 80 for assembling a gas burnerassembly may be represent by the steps of forming a top plate having aplurality of spaced-apart slots adjacent to the periphery of the topplate, at 82, and forming a downwardly-depending, peripheral edge withthe spaced-apart slots, at 84. At 86, a bottom base having a peripheraledge is provided, and at 88, the bottom base is positioned within thedownwardly-depending, peripheral edge with the slots. Thereafter, at 90,portions of the downwardly-depending, peripheral edge of the top plateare displaced or extended to form a plurality of spaced-apart tabs underthe peripheral edge of the bottom base to attach the top plate to thebottom base. Desirably, the components are pressed together prior to andduring the forming of the tabs.

Further, the attachment technique of the present invention may be usedon applications which require the attachment of a first member to asecond member. For example, the first member may have a downwardlydepending, peripheral edge having horizontally- and/orvertically-extending slots which allow a portion of the downwardlydepending, peripheral edge to be displaced and/or expanded under aperipheral edge of the second member. This technique is desirablysuitable where the first member and the second member have differentthermal properties such as thermal expansion rates. The distance betweenadjacent slots may be greater than the length of the slots, and asuitable number of tabs may be formed to provide a gas tight seal withor without a gasket.

FIGS. 8-13 illustrate alternative embodiments of the present inventionfor use in a burner assembly and/or connecting a first member to asecond member. For example, FIG. 8 illustrates a downwardly-dependingperipheral edge 136 having a horizontally-extending slot 134 and avertically-extending slot 135 connected to one end ofhorizontally-extending slot 136. As shown in FIG. 9, a portion 135 ofthe downwardly-depending peripheral edge can be displaced or bentinwardly under a second member 158.

FIGS. 10 and 11 illustrates a downwardly-depending peripheral edge 236having a horizontally-extending slot 134 and a vertically-extending slot137 connected to the middle of horizontally-extending slot 134. As shownin FIG. 11, portions 235 of the downwardly-depending peripheral edge canbe displaced or bent inwardly under a second member 258.

FIGS. 12 and 13 illustrates a downwardly-depending peripheral edge 336having a pair of vertically-extending slots 37. As shown in FIG. 13, aportion 335 of the downwardly-depending peripheral edge can be displacedor bent inwardly under a second member 358.

From the present description, it will be appreciated by those skilled inthe art that first member may have a plurality of spaced-apartindividual vertically-extending slots employed to form the tabs. One ormore of the vertical edges may be displaced or extended over or underthe second member, e.g., by being bent on a 45-degree angle.

Furthermore, the location, size and/or configuration of the slots mayvary so that when the various components are assembled, an interferencetype fit connection will occur along the engaging surface portion of theslot and the bottom base.

The attachment technique of the present invention utilizing tabs alsoallows for independent rates of expansion to occur between the top plateand the bottom base, thereby effectively eliminating thermal stressesthat could result in deformation of the various materials and reducedservice life of the gas burner assembly compared to conventionaltechniques for attaching the top plate to the bottom base of the gasburner assembly. With dissimilar materials such as dissimilar materialshaving different rates of thermal expansion, the attachment techniqueresults in generally self adjusting pressure between the top plate, thegasket, and the bottom base. In addition, the present invention providesa generally fastener-less and tool-less assembly process whicheliminates the need for drilling and tapping holes in the base, anddrilling holes in the top plate while providing a structurally reliableassembled gas burner assembly. Thus, the gas burner assembly may bereadily assembled without the use of conventional fasteners such asbolts. The technique for assembling the gas burner assembly may also beautomated for a uniform assembly compared to manual hand assembly ofattaching bolts.

While the gas burner assembly of the present invention has beendescribed in connection with use in gas fired appliances such as ventedgas fireplace heaters, it will be appreciated that the gas burnerassemblies may also be used in barbeques, outdoor and indoor gas cookinggrills, gas furnaces, gas boilers, gas fireplaces, gas fired spaceheating appliances, and other applications requiring a gas burnerassembly.

Thus, while various embodiments of the present invention have been shownand described, it will be appreciated by those skilled in the art thatmany changes and modifications may be made thereunto without departingfrom the spirit and scope of the invention.

1. A gas burner assembly comprising: a top plate having at least oneport for discharging fuel and a downwardly-depending, peripheral edgehaving a plurality of spaced-apart slots; a bottom base having aperipheral edge disposed within said downwardly-depending, peripheraledge of said top plate; and wherein said top plate is attached to saidbottom base by displacing a portion of said downwardly-depending,peripheral edge adjacent to said slots to form a plurality ofspaced-apart, inwardly-extending tabs disposed under said peripheraledge of said bottom base.
 2. The gas burner assembly of claim 1 whereinsaid top plate and said bottom base comprise different materials havingdifferent rates of thermal expansion.
 3. The gas burner assembly ofclaim 2 wherein said top plate comprises stainless steel, and saidbottom base comprises cast iron.
 4. The gas burner assembly of claim 1wherein said top plate is attached to said bottom base by expanding aportion of said downwardly-depending, peripheral edge under said slotsto form a plurality of spaced-apart, inwardly-extending tabs disposedunder said peripheral edge of said bottom base.
 5. The gas burnerassembly of claim 1 wherein said plurality of inwardly-extending tabscomprises a plurality of spaced-apart, generally inwardly extendingV-shaped tabs.
 6. The gas burner assembly of claim 1 wherein saidplurality of spaced-apart slots comprises a plurality ofhorizontally-extending spaced-apart slots.
 7. The gas burner assembly ofclaim 1 wherein said plurality of spaced-apart slots comprises aplurality of pairs of vertically-extending spaced-apart slots.
 8. Thegas burner assembly of claim 1 wherein said plurality of spaced-aparttabs is operable to maintain a gas tight seal between said top plate andsaid bottom base.
 9. The gas burner assembly of claim 1 furthercomprising a gasket disposed between said bottom base and said topplate.
 10. The gas burner assembly of claim 1 wherein a distance betweenadjacent slots is greater than a length of said slots.
 11. The gasburner assembly of claim 1 further comprising a venturi tube assemblyattached to said bottom base with a tube holder.
 12. A gas firedappliance comprising a housing, and a gas burner assembly of claim 1disposed in said housing.
 13. The gas fired appliance of claim 12further comprising at least one ceramic log disposed above said gasburner assembly.
 14. A gas burner assembly comprising: a top platehaving at least one port for discharging fuel and adownwardly-depending, peripheral edge having a plurality of spaced-apartslots; a bottom base having a peripheral edge disposed within saiddownwardly-depending, peripheral edge of said top plate; a gasketdisposed between said bottom base and said top plate; a venturi tubeassembly; a tube holder for attaching said venture tube assembly to saidbottom base; and wherein a distance between adjacent slots is greaterthan a length of said slots; said top plate is attached to said bottombase by expanding a portion of said downwardly-depending, peripheraledge under said slots to form a plurality of spaced-apart,inwardly-extending tabs disposed under said peripheral edge of saidbottom base; and said gasket and said bottom base are sandwiched betweena bottom surface of said top plate and said tabs and operable tomaintain a gas tight seal between said top plate, said bottom base, andsaid gasket.
 15. The gas burner assembly of claim 14 wherein said topplate and said bottom base comprise different materials having differentrates of thermal expansion.
 16. The gas burner assembly of claim 14wherein said top plate comprises stainless steel, said bottom basecomprises cast iron, and said gasket comprises fiberglass.
 17. The gasburner assembly of claim 14 wherein said plurality of inwardly-extendingtabs comprises a plurality of spaced-apart, generally inwardly extendingV-shaped tabs.
 18. The gas burner assembly of claim 14 wherein saidplurality of spaced-apart slots comprises a plurality ofhorizontally-extending spaced-apart slots.
 19. The gas burner assemblyof claim 14 wherein said plurality of spaced-apart slots comprises aplurality of pairs of vertically-extending spaced-apart slots.
 20. A gasfired appliance comprising a housing, and a gas burner assembly of claim14 disposed in said housing.
 21. The gas fired appliance of claim 20further comprising at least one ceramic log disposed above said gasburner assembly.
 22. A method for assembling a gas burner assembly, themethod comprising: positioning a bottom base having a peripheral edgewithin a top plate having at least one port and having adownwardly-depending, peripheral edge with spaced-apart slots adjacentto the periphery of the top plate; and displacing portions of thedownwardly-depending, peripheral edge of the top plate adjacent to theslots to form a plurality of spaced-apart tabs under the peripheral edgeof the bottom base to attach the top plate to the bottom base.
 23. Themethod of claim 22 wherein the top plate and the bottom base comprisedifferent materials having different rates of thermal expansion.
 24. Themethod of claim 23 wherein the top plate comprises stainless steel, andthe bottom base comprises cast iron.
 25. The method of claim 22 whereinthe displacing comprises expanding a portion of thedownwardly-depending, peripheral edge under the slots to form aplurality of spaced-apart, inwardly-extending tabs disposed under theperipheral edge of the bottom base.
 26. The method of claim 25 whereinthe expanding comprises forming a plurality of spaced-apart, generallyinwardly extending V-shaped tabs.
 27. The method of claim 25 wherein theexpanding comprises using a hydraulically operated tool for applying aforce to expandable portions of the downwardly-depending, peripheraledge.
 28. The method of claim 22 further comprising forming a gas tightseal between the top plate and the bottom base.
 29. The method of claim28 further comprising positioning a gasket between the top plate and thebottom base.
 30. An attachment means comprising: a first member having adownwardly-depending, peripheral edge having a plurality of spaced-apartslots; a second member having a peripheral edge disposed within saiddownwardly-depending, peripheral edge of said first member; wherein saidfirst member is attached to said second member by displacing a portionof said downwardly-depending, peripheral edge adjacent to the slots toform a plurality of spaced-apart, inwardly-extending tabs disposed undersaid peripheral edge of said second member; and said first member andsaid second member comprise different materials having different ratesof thermal expansion.
 31. The attachment means of claim 30 wherein saidfirst member comprises stainless steel, and said second member comprisescast iron.
 32. The attachment means of claim 30 wherein said firstmember is attached to said second member by expanding a portion of saiddownwardly-depending, peripheral edge under said slots to form aplurality of spaced-apart, inwardly-extending tabs disposed under saidperipheral edge of said second member.
 33. The attachment means of claim30 wherein said plurality of inwardly-extending tabs comprises aplurality of spaced-apart, generally inwardly extending V-shaped tabs.34. The attachment means of claim 30 wherein said plurality ofspaced-apart slots comprises a plurality of horizontally-extendingspaced-apart slots.
 35. The attachment means of claim 30 wherein saidplurality of spaced-apart slots comprises a plurality of pairs ofvertically-extending spaced-apart slots.
 36. The attachment means ofclaim 30 wherein said plurality of spaced-apart tabs is operable tomaintain a gas tight seal between said first member and said secondmember.
 37. The attachment means of claim 30 further comprising a gasketdisposed between said first member and said second member.
 38. Theattachment means of claim 30 wherein a distance between adjacent slotsis greater than a length of said slots.
 39. A method for attaching afirst member to a second member, the method comprising: positioning thesecond member having a peripheral edge within the first member having adownwardly-depending, peripheral edge with spaced-apart slots adjacentto the periphery of the first member; and expanding portions of thedownwardly-depending, peripheral edge of the first member adjacent tothe slots to form a plurality of spaced-apart tabs under the peripheraledge of the second member to attach the first member to the secondmember.
 40. The method of claim 39 wherein the first member and thesecond member comprise different materials having different rates ofthermal expansion.
 41. The method of claim 39 wherein the first membercomprises stainless steel, and the second member comprises cast iron.42. The method of claim 39 wherein the expanding comprises expanding aportion of the downwardly-depending, peripheral edge under the slots toform a plurality of spaced-apart, inwardly-extending tabs disposed underthe peripheral edge of the second member.
 43. The method of claim 39wherein the expanding comprises forming a plurality of spaced-apart,generally inwardly extending V-shaped tabs.
 44. The method of claim 39wherein the expanding comprises using a hydraulically operated tool forapplying a force to the expandable portions of the downwardly-depending,peripheral edge.
 45. The method of claim 39 further comprising forming agas tight seal between the first member and the second member.
 46. Themethod of claim 45 further comprising positioning a gasket between thefirst member and the second member.